Porter-Cable CPLDC2540S User's Manual
Contents
1. minutes SPECIFICATIONS Model No CPLDC2540S Horsepower Peak 2 5 Bore 2 363 Stroke 890 Voltage Single Phase 120 Minimum Branch Circuit Requirement 15 amps Fuse Type Time Delay Air Tank Capacity Gallon 4 3 Approximate Cut in Pressure 120 PSIG Approximate Cut out Pressure 150 PSIG SCFM 40 PSIG 5 4 SCFM 90 PSIG 4 0 A CAUTION o air compressor can be operated on a 15 amp circuit 1 Voltage supply to circuit is normal 2 Circuit is not used to supply any other electrical needs lights appliances etc 3 Extension cords comply with specifications in owners manual 4 Circuit is equipped with 15 amp circuit breaker or 15 amp time delay fuse If any of the above conditions cannot be met or if operation of the air compressor repeatedly causes interruption of the power it may be necessary to operate it from a 20 amp circuit It is not necessary to change the cord set A circuit breaker is preferred Use only a fuse or circuit breaker that is the same rating as the branch circuit on which the air compressor is operated If the air compressor is connected to a circuit protected by fuses use dual element time delay fuses A02250 8 ENG ACCESSORIES Accessories for this unit are available at the store the unit was purchased ASSEMBLY To Add Oil To Pump DO NOT ATTEMPT TO OPERATE THIS AIR A CAUTION COMPRESSOR WITHOUT FIRST ADDING OIL TO THE CRANKCASE Serious damage can result from even limited operatio2. AIR OUTLET IF NOT EQUIPPED OF YOUR COMPRESSOR FOLLOW THE EQUIPMENT MANUFACTURERS RECOMMENDATION AND NEVER EXCEED THE MAXIMUM ALLOWABLE PRESSURE RATING OF ATTACHMENTS NEVER USE COMPRESSOR TO INFLATE SMALL LOW PRESSURE OBJECTS SUCH AS CHILDREN S TOYS FOOTBALLS BASKETBALLS ETC HAZARD RISK FROM FLYING OBJECTS WHAT CAN HAPPEN THE COMPRESSED AIR STREAM CAN CAUSE SOFT TISSUE DAMAGE TO EXPOSED SKIN AND CAN PROPEL DIRT CHIPS LOOSE PARTICLES AND SMALL OBJECTS AT HIGH SPEED RESULTING IN PROPERTY DAMAGE OR PERSONAL INJURY A02250 HOW TO PREVENT IT ALWAYS WEAR ANSI Z87 1 APPROVED SAFETY GLASSES WITH SIDE SHIELDS WHEN USING THE COMPRESSOR NEVER POINT ANY NOZZLE OR SPRAYER TOWARD ANY PART OF THE BODY OR AT OTHER PEOPLE OR ANIMALS ALWAYS TURN THE COMPRESSOR OFF AND BLEED PRESSURE FROM THE AIR HOSE AND TANK BEFORE ATTEMPTING MAINTENANCE ATTACHING TOOLS OR ACCESSORIES 4 ENG HAZARD RISK OF ELECTRICAL SHOCK WHAT CAN HAPPEN YOUR AIR COMPRESSOR IS POWERED BY ELECTRICITY LIKE ANY OTHER ELECTRICALLY POWERED DEVICE IF IT IS NOT USED PROPERLY IT MAY CAUSE ELECTRIC SHOCK REPAIRS ATTEMPTED BY UNQUALIFIED PERSONNEL CAN RESULT IN SERIOUS INJURY OR DEATH BY ELECTROCUTION ELECTRICAL GROUNDING FAILURE TO PROVIDE ADEQUATE GROUNDING TO THIS PRODUCT COULD RESULT IN SERIOUS ea w HOW TO PREVENT IT NEVER OPERATE THE COMPRESSOR OUTDOORS WHEN IT IS RAINING OR IN WET CONDITIONS NEVER OPERATE COMPRE
3. electrician Repairs to the cord set or plug MUST be made by a qualified electrician A02250 10 ENG Extension Cords Use extra air hose instead of an extension cord to avoid voltage drop and power loss to the motor and to prevent overheating If an extension cord must be used be sure it is e a3 wire extension cord that has a 3 blade grounding plug and a 3 slot receptacle that will accept the plug on the product e in good condition e no longer than 50 feet e 12 gauge AWG or larger Wire size increases as gauge number decreases 10 AWG and 8 AWG may also be used DO NOT USE 14 OR 16 AWG Voltage and Circuit Protection Refer to the Parts Manual for the voltage and minimum branch circuit requirements Certain air compressors can be operated on a 15 amp circuit if the following conditions are met 1 Voltage supply through branch circuit is 15 amps 2 Circuit is not used to supply any other electrical needs lights appliances etc 3 Extension cords comply with specifications 4 Circuit is equipped with a 15 amp circuit breaker or 15 amp time delay fuse NOTE If compressor is connected to a circuit protected by fuses use only time delay fuses Time delay fuses should be marked D in Canada and T in the US If any of the above conditions cannot be met or if operation of the compressor repeatedly causes interruption of the power it may be necessary to operate it from a 20 amp circuit It is
4. is equipped with a quick connect socket AWARNING Too much air pressure causes a hazardous risk of bursting Check the manufacturer s maximum pressure rating for air tools and accessories The regulator outlet pressure must never exceed the maximum pressure rating How to Start 1 Turn the On Auto Off lever to AUTO and allow tank pressure to build Motor will stop when tank pressure reaches cut out pressure Pull the regulator knob out and turn clockwise to increase pressure When the desired pressure is reached push knob in to lock in place The compressor is ready for use NOTE Always operate the air compressor in well ventilated areas free of gasoline or other combustible vapors If the compressor is being used to operate a sprayer DO NOT place near the spray area A02250 14 ENG MAINTENANCE Customer Responsibilities Daily or after each aa Every Every Every 40 use a hours hours hours Check Safety Valve T T LI rain Tank Tel T Bites ot neck Oi per A S R hange Ol p L T je mm Tr TIT T 1 more frequent in dusty or humid conditions Unit cycles automatically when power is on When CAUTION performing maintenance you may be exposed to voltage sources compressed air or moving parts Personal injuries can occur Before performing any maintenance or repair disconnect power source from the compressor and bleed off all air pressure To ensure efficient operation
5. not necessary to change the cord set 11 ENG A02250 OPERATION Know Your Air Compressor READ THIS OWNER S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR UNIT Compare the illustrations with your unit to familiarize yourself with the location of various controls and adjustments Save this manual for future reference Description of Operation Become familiar with these controls before operating the unit On Auto Off Switch Turn this switch ON to provide automatic power to the pressure switch and OFF to remove power at the end of each use Tank ressure Pressure Switch The pressure switch automatically starts the motor when the me air tank pressure drops below the T a aE factory set cut in pressure It stops the motor when the air tank pressure reaches the factory set cut out pressure Safety Valve If the pressure switch does not shut off the air compressor at its cut out pressure setting the safety Ole 7 valve will protect against high pressure Gauge by popping out at its factory set g i pressure slightly higher than the pressure switch cut out setting Outlet Pressure Gauge The outlet pressure gauge indicates the air pressure available at the outlet side of the regulator This pressure is controlled by the regulator and is always less than or equal to the tank pressure Tank Pressure Gauge The tank pressure gauge indicates the reserve air pressure in the tank Reg
6. plug B and drain oil into a suitable container 4 Replace the oil drain plug B A02250 16 ENG NOTE Use a air compressor oil such as SAE 30 API CG CD heavy duty motor oil Under extreme winter conditions use SAE 10 weight oil 5 Slowly fill crankcase with oil Crankcase capacity is 6 fluid ounces 177 4 ml Oil level should be at the full mark on the dipstick A CAUTION Overfilling with oil will cause premature compressor failure Do not overfill 6 Replace dipstick A Air Filter Inspection and Replacement Hot surfaces Risk of burn Compressor heads are A WARNING exposed when filter cover is removed Allow compressor to cool prior to servicing A dirty air filter will not allow the compressor to operate at full capacity Keep the air filter clean at all times 1 Remove the air filter cover 2 Remove the air filter from filter cover IMPORTANT Do not operate the compressor with the air filter removed 3 Place new air filter into filter cover Refer to the Repair Parts for the correct part number 4 Replace air filter cover and lock into place Motor The motor has an automatic reset thermal overload protector If the motor overheats for any reason the overload protector will shut off the motor The motor must be allowed to cool down before restarting The compressor will automatically restart after the motor cools If the overload protector shuts the motor off frequently check fo
7. regarding servicing arrangements and scheduling may vary depending on the type and size of the product and the availability of repair parts e DO NOT return the defective product to the retailer Retain the original cash register sales receipt as proof of purchase for warranty work e Only Air compressors with 60 and 80 gallon tanks will be inspected at the site of installation e The customer should contact Porter Cable directly if the purchaser does not receive satisfactory results from the authorized warranty service center PORTER CABLE Porter Cable Corporation 4825 Highway 45 North P O Box 2468 Jackson TN 38302 2468 1 888 559 8550 A02250 24 ENG
8. result if the following break in instructions are not closely followed This procedure is required before the air compressor is put into service and when the check valve or a complete compressor pump has been replaced 1 Make sure the On Auto Off lever is in the OFF position 2 Check oil level in pump See Oil paragraph in the Maintenance section for instructions NOTE Pull coupler back until it clicks to prevent air from escaping through the quick connect 13 ENG A02250 Plug the power cord into the correct branch circuit receptacle Refer to Voltage and Circuit Protection paragraph in the Installation section of this manual Open the drain valve fully counter clockwise to permit air to escape and prevent air pressure build up in the air tank during the break in period Move the On Auto Off lever to ON AUTO position The compressor will start Run the compressor for 20 minutes Make sure the drain valve is open and there is minimal air pressure build up in tank After 20 minutes close the drain valve clockwise The air receiver will fill to cut out pressure and the motor will stop The compressor is now ready for use Before Each Start Up 1 2 Place On Auto Off lever to OFF Pull regulator knob out turn counter clockwise until it stops Push knob in to lock in place Attach hose and accessories NOTE The hose or accessory will require a quick connect plug if the air outlet
9. the accessory is used adjust the regulator as instructed in the Operation section NOTE Adjust the regulated pressure under flow conditions while accessory is being used Operate safety valve manually by pulling on ring If valve still leaks it should be replaced Decrease amount of air usage Check the accessory air requirement If it is higher than the SCFM or pressure supplied by your air compressor you need a larger compressor Check and replace if required Remove and clean or replace Tighten fittings Clean or replace air intake filter Do not operate the air compressor with the filter removed Refer to the Air Filter paragraph in the Maintenance section Clean or replace See Air Filter paragraph in the Maintenance section Contact a Trained Service Technician Contact a Trained Service Technician A02250 PROBLEM CAUSE Motor will not run A02250 Motor overload protection switch has tripped Tank pressure exceeds pressure switch cut in pressure Check valve stuck open Loose electrical connections Possible defective motor or starting capacitor Paint spray on internal motor parts Pressure release valve on pressure switch has not unloaded head pressure Fuse blown circuit breaker tripped 22 ENG CORRECTION Let motor cool off and overload switch will automatically reset Motor will start automatically when tank pressure drops b
10. 2250 LIMITED WARRANTY PORTER CABLE CORPORATION warrants to the original purchaser that each new air compressor and service part is free from defects in material and workmanship and agrees to repair or replace under this warranty any defective product or part as follows from the original date of purchase 5 YEARS Limited warranty on 2 stage oil free air compressor pumps that operate at 1725 RPM and 1 year limited warranty on all other parts 3 YEARS Limited warranty on oil lubricated air compressor pumps and 1 year limited warranty on all other parts 1 YEAR Limited warranty on all other air compressor products 90 Day Service parts Engine warranties are the responsibility of the engine manufacturer Warranties of merchandise sold by Porter Cable which has been manufactured by and identified as the product of another company are the responsibility of the manufacturer of that product THIS WARRANTY IS NOT TRANSFERABLE AND DOES NOT COVER e Products sold damaged or incomplete sold as is sold reconditioned or used as rental equipment e Delivery installation or normal adjustments explained in the owner s manual e Damage or liability caused by shipping improper handling improper installation incorrect voltage or improper wiring improper maintenance improper modification or the use of accessories and or attachments not specifically recommended by PORTER CABLE for the tool e Repairs necessary because of operator abuse or neg
11. AINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMAGE READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT HAZARD RISK OF EXPLOSION OR FIRE WHAT CAN HAPPEN IT IS NORMAL FOR ELECTRICAL CONTACTS WITHIN THE MOTOR AND PRESSURE SWITCH TO SPARK IF ELECTRICAL SPARKS FROM COMPRESSOR COME INTO CONTACT WITH FLAMMABLE VAPORS THEY MAY IGNITE CAUSING FIRE OR EXPLOSION RESTRICTING ANY OF THE COMPRESSOR VENTILATION OPENINGS WILL CAUSE SERIOUS OVERHEATING AND COULD CAUSE FIRE UNATTENDED OPERATION OF THIS PRODUCT COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE TO REDUCE THE RISK OF FIRE DO NOT ALLOW THE COMPRESSOR TO OPERATE UNATTENDED 3 ENG HOW TO PREVENT IT ALWAYS OPERATE THE COMPRESSOR IN A WELL VENTILATED AREA FREE OF COMBUSTIBLE MATERIALS GASOLINE OR SOLVENT VAPORS IF SPRAYING FLAMMABLE MATERIALS LOCATE COMPRESSOR AT LEAST 20 FEET AWAY FROM SPRAY AREA AN ADDITIONAL LENGTH OF HOSE MAY BE REQUIRED STORE FLAMMABLE MATERIALS IN A SECURE LOCATION AWAY FROM COMPRESSOR NEVER PLACE OBJECTS AGAINST OR ON TOP OF COMPRESSOR OPERATE COMPRESSOR IN AN OPEN AREA AT LEAST 12 INCHES AWAY FROM ANY WALL OR OBSTRUCTION THAT WOULD RESTRICT THE FLOW OF FRESH AIR TO THE VENTILATION OPENINGS OPERATE COMPRESSOR IN A CLEAN DRY WELL VENTILATED AREA DO NOT OPERATE UNIT INDOORS OR IN ANY CONFINED AREA ALWAYS REMAIN IN ATTENDANCE WITH THE PRODUCT WHEN
12. ENT ACCIDENTAL MOVEMENT OF THE UNIT NEVER OPERATE COMPRESSOR ON A ROOF OR OTHER ELEVATED POSITION USE ADDITIONAL AIR HOSE TO REACH HIGH LOCATIONS HAZARD RISK OF PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR Fire Inhalation Damage to Vehicle Surfaces WHAT CAN HAPPEN OIL CAN LEAK OR SPILL AND COULD RESULT IN FIRE OR BREATHING HAZARD SERIOUS INJURY OR DEATH CAN RESULT OIL LEAKS WILL DAMAGE CARPET PAINT OR OTHER SURFACES IN VEHICLES OR TRAILERS A02250 HOW TO PREVENT IT ALWAYS PLACE COMPRESSOR ON A PROTECTIVE MAT WHEN TRANSPORTING TO PROTECT AGAINST DAMAGE TO VEHICLE FROM LEAKS REMOVE COMPRESSOR FROM VEHICLE IMMEDIATELY UPON ARRIVAL AT YOUR DESTINATION 6 ENG HAZARD RISK OF UNSAFE OPERATION WHAT CAN HAPPEN HOW TO PREVENT IT UNSAFE OPERATION OF YOUR AIR REVIEW AND UNDERSTAND ALL COMPRESSOR COULD LEAD TO SERIOUS IN INSTRUCTIONS AND WARNINGS IN THIS JURY OR DEATH TO YOU OR OTHERS MANUAL BECOME FAMILIAR WITH THE OPERATION AND CONTROLS OF THE AIR COMPRESSOR KEEP OPERATING AREA CLEAR OF ALL PERSONS PETS AND OBSTACLES KEEP CHILDREN AWAY FROM THE AIR COMPRESSOR AT ALL TIMES DO NOT OPERATE THE PRODUCT WHEN FATIGUED OR UNDER THE INFLUENCE OF ALCOHOL OR DRUGS STAY ALERT AT ALL TIMES NEVER DEFEAT THE SAFETY FEATURES OF THIS PRODUCT EQUIP AREA OF OPERATION WITH A FIRE EXTINGUISHER DO NOT OPERATE MACHINE WITH MISSING BROKEN OR UNAUTHORIZED PARTS 7 ENG A02250 GLOSSARY Become fam
13. IT IS OPERATING ALWAYS DISCONNECT ELECTRICAL POWER BY MOVING PRESSURE SWITCH LEVER TO THE OFF POSITION AND DRAIN TANK DAILY OR AFTER EACH USE A02250 HAZARD RISK OF BURSTING AIR TANK THE FOLLOWING CONDITIONS COULD LEAD TO A WEAKENING OF THE TANK AND RESULT IN A VIOLENT TANK EXPLOSION AND COULD CAUSE PROPERTY DAMAGE OR SERIOUS INJURY WHAT CAN HAPPEN 1 FAILURE TO PROPERLY DRAIN CONDENSED WATER FROM THE TANK CAUSING RUST AND THINNING OF THE STEEL TANK 2 MODIFICATIONS OR ATTEMPTED REPAIRS TO THE TANK 3 UNAUTHORIZED MODIFICATIONS TO THE UNLOADER VALVE SAFETY VALVE OR ANY OTHER COMPONENTS WHICH CONTROL TANK PRESSURE 4 EXCESSIVE VIBRATION CAN WEAKEN THE AIR TANK AND CAUSE RUPTURE OR EXPLOSION ATTACHMENTS amp ACCESSORIES EXCEEDING THE PRESSURE RATING OF AIR TOOLS SPRAY GUNS AIR OPERATED ACCESSORIES TIRES AND OTHER INFLATABLES CAN CAUSE THEM TO EXPLODE OR FLY APART AND COULD RESULT IN SERIOUS INJURY HOW TO PREVENT IT DRAIN TANK DAILY OR AFTER EACH USE IF TANK DEVELOPS A LEAK REPLACE IT IMMEDIATELY WITH A NEW TANK OR REPLACE THE ENTIRE COMPRESSOR NEVER DRILL INTO WELD OR MAKE ANY MODIFICATIONS TO THE TANK OR ITS ATTACHMENTS THE TANK IS DESIGNED TO WITHSTAND SPECIFIC OPERATING PRESSURES NEVER MAKE ADJUSTMENTS OR PARTS SUBSTITUTIONS TO ALTER THE FACTORY SET OPERATING PRESSURES FOR ESSENTIAL CONTROL OF AIR PRESSURE YOU MUST INSTALL A PRESSURE REGULATOR AND PRESSURE GAUGE TO THE
14. Instruction manual ESPANOL P GINA 25 FRANGAIS PAGE 49 Direct Drive Oil Lube Portable Air Compressor To learn more about Porter Cable visit our website at http www porter cable com PORTER CABLE PROFESSIONAL POWER TOOLS Copyright 2004 Porter Cable Corporation CPLDC2540S IMPORTANT Please make certain that the person who is to use this equipment carefully reads and understands these instructions before starting operations The Model and Serial No plate is located on the frame Record these numbers in the spaces below and retain for future reference Model No Type Serial No Part No A02250 041 0 SAFETY GUIDELINES DEFINITIONS This manual contains information that is important for you to know and understand This information relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize this information we use the symbols below Please read the manual and pay attention to these sections WN Niels indicates an PNY NT so indicates a potentially imminently hazardous hazardous situation situation which if not avoided will which if not avoided may result in result in death or serious injury minor or moderate injury INNTA Negl iidicates a potentially YN h q Used without the hazardous situation safety alert symbol which if not avoided could result in indicates a potentially hazardous death or serious injury situation which if not avoided may
15. SSOR WITH PROTECTIVE COVERS REMOVED OR DAMAGED ANY ELECTRICAL WIRING OR REPAIRS REQUIRED ON THIS PRODUCT SHOULD BE PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL IN ACCORDANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES MAKE CERTAIN THAT THE ELECTRICAL CIRCUIT TO WHICH THE COMPRESSOR IS INJURY OR DEATH FROM ELECTROCUTION CONNECTED PROVIDES PROPER SEE CROUNDING INSTRUCTIONS ELECTRICAL GROUNDING CORRECT VOLTAGE AND ADEQUATE FUSE PROTECTION HAZARD RISK TO BREATHING WHAT CAN HAPPEN THE COMPRESSED AIR DIRECTLY FROM YOUR COMPRESSOR IS NOT SAFE FOR BREATHING THE AIR STREAM MAY CONTAIN CARBON MONOXIDE TOXIC VAPORS OR SOLID PARTICLES FROM THE TANK BREATHING THESE CONTAMINANTS CAN CAUSE SERIOUS INJURY OR DEATH SPRAYED MATERIALS SUCH AS PAINT PAINT SOLVENTS PAINT REMOVER INSECTICIDES WEED KILLERS MAY CONTAIN HARMFUL VAPORS AND POISONS 5 ENG HOW TO PREVENT IT AIR OBTAINED DIRECTLY FROM THE COMPRESSOR SHOULD NEVER BE USED TO SUPPLY AIR FOR HUMAN CONSUMPTION IN ORDER TO USE AIR PRODUCED BY THIS COMPRESSOR FOR BREATHING SUITABLE FILTERS AND IN LINE SAFETY EQUIPMENT MUST BE PROPERLY INSTALLED IN LINE FILTERS AND SAFETY EQUIPMENT USED IN CONJUNCTION WITH THE COMPRESSOR MUST BE CAPABLE OF TREATING AIR TO ALL APPLICABLE LOCAL AND FEDERAL CODES PRIOR TO HUMAN CONSUMPTION WORK IN AN AREA WITH GOOD CROSS VENTILATION READ AND FOLLOW THE SAFETY INSTRUCTIONS PROVIDED ON THE LABEL OR SAFETY DATA SHEETS FOR
16. THE MATERIAL YOU ARE SPRAYING USE A NIOSH MSHA APPROVED RESPIRATOR DESIGNED FOR USE WITH YOUR SPECIFIC APPLICATION A02250 HAZARD RISK OF BURNS WHAT CAN HAPPEN TOUCHING EXPOSED METAL SUCH AS THE COMPRESSOR HEAD OR OUTLET TUBES CAN RESULT IN SERIOUS BURNS gt n HOW TO PREVENT IT NEVER TOUCH ANY EXPOSED METAL PARTS ON COMPRESSOR DURING OR IMMEDIATELY AFTER OPERATION COMPRESSOR WILL REMAIN HOT FOR SEVERAL MINUTES AFTER OPERATION DO NOT REACH AROUND PROTECTIVE SHROUDS OR ATTEMPT MAINTENANCE UNTIL UNIT HAS BEEN ALLOWED TO COOL HAZARD RISK FROM MOVING PARTS WHAT CAN HAPPEN MOVING PARTS SUCH AS THE PULLEY FLYWHEEL AND BELT CAN CAUSE SERIOUS INJURY IF THEY COME INTO CONTACT WITH YOU OR YOUR CLOTHING ATTEMPTING TO OPERATE COMPRESSOR WITH DAMAGED OR MISSING PARTS OR ATTEMPTING TO REPAIR COMPRESSOR WITH PROTECTIVE SHROUDS REMOVED CAN EXPOSE YOU TO MOVING PARTS AND CAN RESULT IN SERIOUS INJURY HOW TO PREVENT IT NEVER OPERATE THE COMPRESSOR WITH GUARDS OR COVERS WHICH ARE DAMAGED OR REMOVED ANY REPAIRS REQUIRED ON THIS PRODUCT SHOULD BE PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL HAZARD RISK OF FALLING WHAT CAN HAPPEN A PORTABLE COMPRESSOR CAN FALL FROM A TABLE WORKBENCH OR ROOF CAUSING DAMAGE TO THE COMPRESSOR AND COULD RESULT IN SERIOUS INJURY OR DEATH TO THE OPERATOR lt tl HOW TO PREVENT IT ALWAYS OPERATE COMPRESSOR IN A STABLE SECURE POSITION TO PREV
17. and longer life of the air compressor outfit a routine maintenance schedule should be prepared and followed The following routine maintenance schedule is geared to an outfit in a normal working environment operating on a daily basis If necessary the schedule should be modified to suit the conditions under which your compressor is used The modifications will depend upon the hours of operation and the working environment Compressor outfits in an extremely dirty and or hostile environment will require a greater frequency of all maintenance checks NOTE See Operation section for the location of controls To Check Safety Valve AWARNING If the safety valve does not work properly over pressurization may occur causing air tank rupture or an explosion 1 Before starting compressor pull the ring on the safety valve to make sure that the safety valve operates freely If the valve is stuck or does not operate smoothly it must be replaced with the same type of valve To Drain Tank 1 Set the On Auto Off lever to OFF 2 Pull the regulator knob out and turn clockwise to set the outlet pressure to zero p Remove the air tool or accessory Pull ring on safety valve allowing air to bleed from the tank until tank pressure is approximately 20 psi Release safety valve ring 15 ENG A02250 5 Drain water from air tank by opening drain valve counter clockwise on bottom of tank NOTE Tilt tank forward to drain tank completel
18. e motor has an automatic reset thermal overload protector If the motor overheats for any reason the overload protector will shut off the motor The motor must be allowed to cool down before restarting The compressor will automatically restart after the motor cools Air Intake Filter This filter is designed to clean air coming into the pump This filter must always be clean and ventilation openings free from obstructions See Maintenance Check Valve When the air compressor is operating Air intake the check valve is open allowing compressed airto Filter enter the air tank When the air compressor reaches cut out pressure the check valve closes allowing air pressure to remain inside the air tank Pressure Release Valve The pressure release valve located on the side of the pressure switch is designed to automatically release compressed air from the compressor head and the outlet tube when the air compressor reaches cut out pressure or is shut off The pressure release valve allows the motor to restart freely When the motor stops running air will be heard Pressure escaping from this valve for a few seconds No air Release should be heard leaking when the motor is running or ds continuous leaking after unit reaches cut out pressure How to Use Your Unit How to Stop 1 Set the On Auto Off lever to OFF Before Starting Break in Procedure AWARNING Serious damage may
19. elow cut in pressure of pressure switch Remove and clean or replace Check wiring connection inside pressure switch and terminal box area Have checked by a Trained Service Technician Have checked by a Trained Service Technician Do not operate the compressor in the paint spray area See flammable vapor warning Bleed the line by pushing the lever on the pressure switch to the off position if the valve does not open replace switch 1 Check fuse box for blown fuse and replace as necessary Reset circuit breaker Do not use a fuse or circuit breaker with higher rating than that specified for your particular branch circuit 2 Check for proper fuse You should use a time delay fuse 3 Check for low voltage conditions and or proper extension cord 4 Disconnect the other electrical appliances from Circuit or operate the compressor on its own branch circuit PROBLEM CAUSE Knocking Noise Possible defect in safety Squealing Sound valve Defective check valve Compressor mounting screws loose Carbon build up in pump Compressor pump has no oil 23 ENG CORRECTION Operate safety valve manually by pulling on ring If valve still leaks it should be replaced Remove and clean or replace Tighten mounting screws see Parts manual for torque specifications Have checked by a Trained Service Technician See Oil Checking paragraph in the Maintenance section A0
20. iliar with these terms before operating the unit CFM Cubic feet per minute SCFM Standard cubic feet per minute a unit of measure of air delivery PSIG Pounds per square inch gauge a unit of measure of pressure Code Certification Products that bear one or more of the following marks UL CUL ETL CETL have been evaluated by OSHA certified independent safety laboratories and meet the applicable Underwriters Laboratories Standards for Safety Cut In Pressure While the motor is off air tank pressure drops as you continue to use your accessory When the tank pressure drops to a certain low level the motor will restart automatically The low pressure at which the motor automatically restarts is called cut in pressure Cut Out Pressure When an air compressor is turned on and begins to run air pressure in the air tank begins to build It builds to a certain high pressure before the motor automatically shuts off protecting your air tank from pressure higher than its capacity The high pressure at which the motor shuts off is called cut out pressure Branch Circuit Circuit carrying electricity from electrical panel to outlet DUTY CYCLE Porter Cable air compressors should be operated on not more than a 50 duty cycle This means an air compressor that pumps air more than 50 of one hour is considered misuse because the air compressor is undersized for the required air demand Maximum compressor pumping time per hour is 30
21. ligence or the failure to install operate maintain and store the product according to the instructions in the owner s manual e Damage caused by cold heat rain excessive humidity corrosive environments and materials or other contaminants Expendable items that become worn during normal use such as drain valves fuses filters belts air cleaners spark plugs engine oil and pump oil Cosmetic defects that do not interfere with tool functionality Freight costs from customer to Porter Cable Repair and transportation costs of products or parts determined not to be defective ANY INCIDENTAL INDIRECT OR CONSEQUENTIAL LOSS DAMAGE OR EXPENSE THAT MAY RESULT FROM ANY DEFECT FAILURE OR MALFUNCTION OF THE PRODUCT Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you e IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you WARRANTY SERVICE is available by delivering or shipping the defective product or part to any Porter Cable authorized warranty service location To determine the nearest authorized warranty service location call the toll free number 1 888 559 8550 24 hours a day 7 days a week Specific instructions
22. n unless filled with oil and broken in correctly Make sure to closely follow initial start up procedures COMPRESSORS ARE SHIPPED WITHOUT OIL A small A CAUTION amount of oil may be present in the pump upon receipt of the air compressor This is due to plant testing and does not mean the pump contains oil Multi Viscosity motor oils like 10W 30 should not be A CAUTION used in an air compressor They leave carbon deposits on critical components thus reducing performance and compressor life Use air compressor oil only NOTE Use an air compressor oil such as SAE 30 API CG CD heavy duty motor oil Under extreme winter conditions use SAE 10 weight oil 1 Place unit on a level surface Drain tank to release air pressure before removing the dipstick Make sure air vent B in dipstick is free from debris If air vent is blocked pressure can build in crankcase causing damage to air compressor and possible personal injury 2 Remove dipstick A and slowly fill crankcase with oil Crankcase capacity is 6 fluid ounces 177 4 ml Oil level should be at the full mark on the dipstick NOTE If the oil is added too quickly it will overflow and appear to be full 3 Replace dipstick 9 ENG A02250 INSTALLATION HOW TO SET UP YOUR UNIT Location of the Air Compressor Locate the air compressor in a clean dry and well ventilated area The air compressor should be located at least 12 away from the wall or othe
23. n a constant air leak valve at the pressure release valve when there is pressure in the tank and the compressor is shut off Replace check valve Refer the To Replace or Clean Check Valve in the Service and Adjustment section Air leaks at Defective pressure switch Contact a Trained Service pressure switch release valve Technician release valve if equipped Air leaks in air Defective air tank Air tank must be replaced tank or at air Do not repair the leak tank welds Do not drill into weld or otherwise modify air tank or it will weaken The tank can rupture or explode Air leaks Leaking seal Contact a Trained Service between head Technician and valve plate A02250 20 ENG PROBLEM CAUSE Pressure reading lt is normal for some on the regulated pressure drop to occur pressure gauge if equipped drops when an accessory IS used Air leak from safety valve Possible defect in safety valve Prolonged excessive use of Compressor is not supplying air enough air to Compressor is not large operate enough for air requirement accessories Hole in hose Check valve restricted Air leaks Restricted air intake filter Restricted air intake Dirty air filter Regulator knob has continuous air leak Damaged regulator Regulator will Damaged regulator not shut off air outlet 21 ENG CORRECTION If there is an excessive amount of pressure drop when
24. n counterclockwise using an adjustable wrench Note the orientation of the elbow fitting for reassembly 7 Using a screwdriver carefully push the valve disc up and down NOTE The valve disc should move freely up and down on a spring which holds the valve disc in the closed position if not the f check valve needs to be Screwdriver In Open position cleaned or replaced nothing is visible 8 Clean or replace the check valve A solvent such as paint or varnish remover can be used to clean the check valve 9 Apply sealant to the check valve threads Reinstall the check valve and elbow fitting turn clockwise 10 Replace the pressure release tube Tighten nut 11 Replace the outlet tube and tighten nut 12 Perform the Break in Procedure See Break in Procedure in the Operation section In closed position disc is visible A02250 18 ENG STORAGE Before you store the air compressor make sure you do the following 1 Review the Maintenance section on the preceding pages and perform scheduled maintenance as necessary Set the On Auto Off lever to OFF Turn the regulator counterclockwise and set the outlet pressure to zero Remove the air tool or accessory dl P Pull ring on safety valve allowing air to bleed from the tank until tank pressure is approximately 20 psi Release safety valve ring 6 Drain water from air tank by opening drain valve on bottom of tank AWARNING Water will condense i
25. n the air tank If not drained water will corrode and weaken the air tank causing a risk of air tank rupture 7 After the water has been drained close the drain or drain valve NOTE If drain valve is plugged release all air pressure The valve can then be removed cleaned then reinstalled 8 Protect the electrical cord and air hose from damage Such as being stepped on or run over Wind them loosely around the compressor handle If so equipped Store the air compressor in a clean and dry location 19 ENG A02250 TROUBLESHOOTING AWARNING Performing repairs may expose voltage sources moving parts or compressed air sources moving parts or compressed air sources Personal injury may occur Prior to attempting any repairs unplug the air compressor and bleed off all air tank air pressure PROBLEM CAUSE CORRECTION Excessive tank Pressure switch does not Move On Auto Off lever to pressure shut off motor when the OFF position if the safety valve compressor reaches cut outfit does pops off out pressure not shut off contact a Trained Service Technician Pressure switch cut out Contact a Trained Service too high Technician Air leaks at Tube fittings are not tight Tighten fittings where air can fittings enough be heard escaping Check fittings with soapy water solution DO NOT OVERTIGHTEN Air leaks at or Check valve seat damaged A defective check valve inside check results i
26. r a possible voltage problem Low voltage can also be suspected when 1 The motor does not get up to full power or speed 2 Fuses blow out when starting the motor lights dim and remain dim when motor is started and is running 17 ENG A02250 SERVICE AND ADJUSTMENTS A WARNING Unit cycles automatically when power is on When doing Maintenance you may be exposed to voltage sources compressed air or moving parts Personal injuries can occur Before performing any Maintenance or repair unplug the compressor and bleed off all air pressure ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE PERFORMED BY TRAINED SERVICE TECHNICIAN WARNING Before servicing Unplug or disconnect electrical supply to the air compressor Bleed tank of pressure Allow the air compressor to cool To Replace or Clean Check Valve 1 Release all air pressure from air tank See To Drain Tank in the Maintenance section 2 Unplug outfit 3 Using an adjustable wrench loosen outlet tube nut at air tank and pump Carefully move outlet tube away IN from check valve 4 Using an adjustable wrench loosen pressure relief tube nut at air tank and pressure switch Carefully move pressure relief tube away from check valve 5 Unscrew the check valve turn mnd counterclockwise using a 7 8 open r ga end wrench Note the orientation for reassembly m EG eS 6 Unscrew elbow fitting from the T check valve tur
27. r obstructions that will interfere with the flow of air The air filter must be kept clear of obstructions which could reduce air flow to the air compressor 6 The air compressor requires fresh air flow for proper cooling DO NOT ALLOW THE COMPRESSOR TO GET WET GROUNDING INSTRUCTIONS AWARNING RISK OF ELECTRICAL SHOCK In the event of a short circuit grounding reduces the risk of shock by providing an escape wire for the electric current This air compressor must be properly grounded The portable air compressor is equipped with a cord having a grounding wire with an appropriate grounding plug see following illustrations 1 The cord set and plug with this unit contains a grounding pin This plug MUST be used with a grounded outlet IMPORTANT The outlet being used must be installed and grounded in accordance with all local codes and ordinances 2 Make sure the outlet being used has the same configuration as the grounded plug DO NOT USE AN ADAPTER See illustration f 3 Inspect the plug and cord before each QR use Do not use if there are signs of damage Grounding Pin 4 If these grounding instructions are not completely understood or if in doubt as to whether the compressor is properly grounded have the installation checked by a qualified electrician AWARNING Sok GROUNDING CAN RESULT IN ELECTRICAL Do not modify the plug provided If it does not fit the available outlet a correct outlet should be installed by a qualified
28. result in property damage IMPORTANT SAFETY INSTRUCTIONS AWARNING Some dust created by power sanding sawing grinding drilling and other construction activities contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Some example of these chemicals are lead from lead based paints crystalline silica from bricks and cement and other masonry products arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipment always wear MSHA NIOSH approved properly fitting face mask or respirator when using such tools When using air tools basic safety precautions should always be followed to reduce the risk of of personal injury READ AND FOLLOW ALL INSTRUCTIONS This tool was designed for certain applications Porter Cable strongly recommends that this tool NOT be modified and or used for any application other than for which it was designed If you have any questions relative to its application DO NOT use the tool until you have written Porter Cable and we have advised you Technical Service Manager Porter Cable Corporation 4825 Highway 45 North P O Box 2468 Jackson TN 38302 2468 A02250 2 ENG IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS IMPROPER OPERATION OR M
29. ulator Controls the air pressure shown on the outlet pressure gauge Pull the knob out and turn clockwise to increase pressure and counterclockwise to decrease pressure When the desired pressure is reached push knob in to lock in place Universal Quick Connect Body The universal quick connect body accepts the three most popular styles of quick connect plugs Industrial automotive Tru flate and ARO One hand push to connect operation makes connections simple and easy The two quick connect bodies allow the use of two tools at the same time Drain Valve The drain valve is located at the base of the air tank and is used to drain condensation at the end of each use Cooling System not shown This compressor contains an advanced design cooling system At the heart of this cooling system is an engineered fan It is perfectly normal for this fan to blow air over the pump head cylinder sleeve and crankcase You know the cooling system is working when air is being expelled Air Compressor Pump not shown Compresses air into the air tank Working air is not available until the compressor has raised the air tank pressure above that required at the air outlet A02250 12 ENG Drain Valve Dipstick Indicates the amount of oil in the pump the mark indicates full and the mark indicates oil needs to be added See Oil paragraphs in the Maintenance section for instructions Motor Thermal Overload Protector not shown Th
30. y AWARNING Water will condense in the air tank If not drained water will corrode and weaken the air tank causing a risk of air tank rupture 6 After the water has been drained close the drain valve clockwise The air compressor can now be stored NOTE If drain valve is plugged release all air pressure The valve can then be removed cleaned then reinstalled Oil AWARNING Drain tank to release air pressure before removing the dipstick or oil drain plug Compressor head and cylinder sleeve are very hot Do not touch AWARNING Checking 1 Set the On Auto Off lever to OFF 2 Remove dipstick A and check oil on dipstick for visual signs of contaminants water dirt etc Make sure air vent C in dipstick is free from debris If air vent is blocked pressure can build in crankcase causing damage to air compressor and possible personal injury 3 Wipe oil from dipstick 4 Replace dipstick and allow oil to collect on dipstick 5 Remove dipstick and check oil level on dipstick mark indicates full and the mark indicates add oil If oil level is below mark slowly add oil until it reaches the full mark on the dipstick NOTE Use a air compressor oil such as SAE 30 API CG CD heavy duty motor oil Under extreme winter conditions use SAE 10 weight oil 6 Replace dipstick A Changing 1 Set the On Auto Off lever to OFF 2 Remove the dipstick A 3 Remove the oil drain
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